Compressed air stands as a fundamental resource within industrial operations, powering everything from hand-held pneumatic tools to large-scale CNC machines. Due to its versatility, it has been used in most of the manufacturing facilities, including automotive, food, fabrication, chemical and textile plants. In United States, compressed air itself accounts for 10% of total industrial energy consumption. Given its pivotal role in manufacturing processes and its notable energy and environmental footprint, it becomes imperative to ensure the efficient operation of compressed air systems. One of the primary inefficiencies in industrial compressed air systems is leakage, which can result in significant energy wastage. Air leaks alone are estimated to account for 20-30% of a compressor’s output on average, creating considerable operational costs and increasing the environmental burden. Hence, proactive leak detection and repair are critically important for achieving optimal energy efficiency and reducing operational costs. Most manufacturing facilities lack the in-house expertise or equipment to perform comprehensive compressed air assessments and therefore depend on external auditors to conduct system evaluations, identify leaks, and provide repair recommendations. This paper presents an analysis of actual compressed air audit information collected from several manufacturing plants of different sizes and operational focuses. By examining real-world audit results from third-party vendor, this study provides valuable insights into thedistribution of leak locations, rates of leakage, and the costs associated with leak repair. Depending on the nature and location of leaks, some are easy and cost effective to fix with minimal effort, while some requires maintenance work order to address it properly. The analysis identifies common areas prone to leakage, quantifying their contributions to overall artificial demand within the compressed air system. Understanding these prevalent leakage zones can help facilities focus on high-priority areas, optimizing both maintenance efforts and resource allocation. Furthermore, the study examines a comprehensive database from Department of Energy’s (DOE) Industrial Training and Assessment Centers (ITACs), a network of centers across the nation that provide no-cost energy assessments to small-to-medium sized manufacturers. It shares insights into energy savings, payback period and estimated leak rates by summarizing all the recommendation on air leaks repair made by centers in last five years. A study on findings from ITAC database and external expert compressed air auditor are presented, offering a broader perspective on industry-wide practices and the variability in existing compressed air leaks across industrial sectors. By identifying prevalent leakage areas along with its impact of leak rates and quantifying the costs of repair, this research offers practical recommendations to improve the efficiency of compressed air systems and reduce their environmental impact.